METHOD FOR MONITORING AN AUTOMATION SYSTEM

Abstract

The present disclosure includes a method for monitoring an automation system having a multiplicity of field devices arranged in a spatially distributed fashion and configured to acquire or set a primary process variable that is dependent on the process. The field devices are also configured to each acquire at least one secondary environmental variable and have at least one superordinate process control unit for controlling the process. The method includes transmitting the acquired environmental variables to a superordinate database and analysis platform and monitoring the automation system using the database and analysis platform. To monitor the automation system, the database and analysis platform compares the acquired transmitted secondary environmental variables with comparative environmental variables which represent a usual state of the automation system, in order to detect an unusual state in the automation system.

Claims

1-20. (canceled)

21. A method for monitoring an automation technology automation system which is configured to carry out a process, wherein the automation system comprises at least the following: a multiplicity of field devices arranged in a spatially distributed fashion in the automation system, each field device configured to acquire or to set a primary process variable that is dependent on the process, wherein the field devices are each further configured to acquire at least one secondary environmental variable; and at least one superordinate process control unit for controlling the process, wherein the process control unit is in data communication with the multiplicity of field devices such that at least the primary process variable can be communicated between the process control unit and the multiplicity of field devices in order to control the process; wherein the method includes the following steps: transmitting the acquired environmental variables, wherein at least from parts of the multiplicity of field devices, the acquired environmental variable is transmitted to a superordinate database and analysis platform; and monitoring the automation system by means of the database and analysis platform, wherein in order to monitor the automation system, the database and analysis platform compares the acquired transmitted secondary environmental variables with comparative environmental variables which represent a usual state of the automation system, in order thereby to detect an unusual state in the automation system.

22. The method of claim 21, wherein the acquired environmental variables are transmitted with an information density, and, if the unusual state is detected, the information density is increased.

23. The method of claim 22, wherein the information density is increased by increasing or enhancing a transmission frequency with which the acquired environmental variables are transmitted to the superordinate database and analysis platform.

24. The method of claim 22, wherein the information density is increased by transmitting the acquired environmental variables to the database and analysis platform from further parts of the multiplicity of field devices.

25. The method of claim 21, wherein the database and analysis platform is provided with a field-device-specific comparative variable, which for each corresponding field device maps the secondary environmental variable under standard conditions, and wherein the field-device-specific comparative variables are used by the database and analysis platform to compare the acquired secondary environmental variables with comparative environmental variables.

26. The method of claim 25, wherein the field-device-specific comparative variables are generated in that secondary environmental variables are acquired by the corresponding field device when the automation system is started up or when the corresponding field device is calibrated.

27. The method of claim 21, wherein in the event that the unusual state is detected, a location where the unusual state occurs is spatially or geographically isolated in the automation system.

28. The method of claim 22, wherein a TAG number or measuring point identification number is assigned to the multiplicity of field devices arranged in a distributed fashion and an assignment of the respective field device to the respective TAG number or measuring point identification number is provided to the database and analysis platform.

29. The method of claim 28, wherein, based on the respective field device to the respective TAG number, the location where the unusual state occurs is spatially or geographically isolated in the automation system.

30. The method of claim 28, wherein the information density is increased on the basis of the respective field device with respect to the respective TAG number and the spatial or geographic isolation of the location where the unusual state occurs.

31. The method of claim 21, wherein in the event that the unusual state is detected, the unusual state is evaluated and assigned a priority.

32. The method of claim 21, wherein the database and analysis platform is self-learning, and learns whether a currently detected unusual state will also be handled as an unusual state in the future.

33. The method of claim 21, wherein the secondary environmental variable is acquired by the respective field device in the form of a temperature variable, a gas composition, image information, or a vibration variable.

34. An automation technology field device, having: at least one sensor element or control element configured to acquire or set a primary process variable that is dependent on the process; at least one environmental sensor element configured to acquire a secondary environmental variable; and a field device electronic unit configured to receive the primary process variable from a superordinate process control unit or send it to the process control unit, and further configured to send the secondary environmental variable to a superordinate database and analysis platform.

35. The field device of claim 34, wherein the environmental sensor element is configured to acquire a temperature variable, a gas composition, image information, or a vibration variable.

36. The field device of claim 34, wherein the environmental sensor element comprises a position sensor.

37. The field device of claim 34, wherein the field device electronic unit is further configured to wirelessly transmit the secondary environmental variable to the superordinate database and analysis platform.

38. The field device of claim 34, wherein the field device electronic unit is further configured to transmit the environmental variable at different transmission frequencies.

39. The field device of claim 34, further comprising a GPS sensor element for determining a spatial or geographic position of the field device.

40. An automation technology system, including: a multiplicity of field devices arranged in a spatially distributed fashion in an automation system, each of which includes: at least one sensor element or control element configured to acquire or set a primary process variable that is dependent on a process; at least one environmental sensor element configured to acquire a secondary environmental variable; and a field device electronic unit configured to receive the primary process variable from a superordinate process control unit or send it to the process control unit, and further configured to send the secondary environmental variable to a superordinate database and analysis platform; at least one superordinate process control unit for controlling the process, which is in data communication with the multiplicity of field devices in such a way that at least the primary process variable can be communicated between the process control unit and the multiplicity of field devices so that a process running in the automation technology system can be controlled by the process control unit; and a database and analysis platform in data communication with the multiplicity of field devices in such a way that the acquired environmental variables can be communicated from the multiplicity of field devices to the database and analysis platform and the database and analysis platform is configured to compare the acquired transmitted secondary environmental variables with comparative environmental variables which represent a usual state of the automation system to detect an unusual state in the automation system.

Description

[0041] The invention is explained in more detail based upon the following drawings. These show:

[0042] FIG. 1: a schematic representation of a multiplicity of field devices each having an exemplary signal profile of the secondary environmental variable acquired by the corresponding field device,

[0043] FIG. 2: a schematic representation of an automation technology system comprising an automation system with five field devices arranged spatially differently from one another as well as a database and analysis platform which is arranged outside the automation system in the example shown, and

[0044] FIG. 3: five exemplary signal profiles of the secondary environmental variable, each of which was acquired by a field device of the automation system shown in FIG. 2 and transmitted to a database and analysis platform for monitoring the system.

[0045] FIG. 1 shows a schematic representation of a multiplicity of field devices 101-105 according to the invention and, arranged next to the field devices in each case, an exemplary signal profile of the secondary environmental variables 201-205 acquired by the respective field device 101-105. All field devices 101-105 are designed in such a way that each of them has at least one sensor element or control element 240 which is configured to acquire or set a process variable F, p, T, R and D that is dependent on the process. In this case, a primary process variable F, p, T, R, D dependent on the process is a variable which is used by a superordinate unit 300, for example a memory-programmable logic controller, SPS for short, to control a process to be performed in an automation system 500 in which the field devices 101-105 are arranged. For this purpose, five field devices 101, 102, 103, 104 and 105 are shown as examples in FIG. 1, each of which is configured to acquire or to set a respective different process variable.

[0046] This is indicated in FIG. 1 by the symbols F, p, T, R and D, wherein the symbol F is intended to demonstrate that the field device 101 acquires a flow of a medium as the process variable dependent on the process, the symbol p that the field device 102 acquires a pressure of the medium as the process variable dependent on the process, the symbol T that the field device 103 acquires a temperature of the medium as the process variable dependent on the process, the symbol R that the field device 104 controls or sets a flow of the medium as process variable dependent on the process, and symbol D that the field device 105 conveys/drives the medium as process variable dependent on the process controls.

[0047] Furthermore, according to the invention, all field devices 101-015 each have at least one environmental sensor element 250, which is configured to acquire a secondary environmental variable 201-205. The secondary environmental variable 201-205 is in this case a variable which is substantially independent of the process, i.e., it is substantially independent of the primary process variable F, p, T, R, D and thus does not relate to a measured value and/or control value for controlling or setting the process. Examples of such secondary environmental variables 201-205 are: a temperature variable of an environmental temperature of the field device or an environmental temperature variable, a gas composition variable of an environmental medium of the field device or an environmental gas composition variable, image information comprising a representation of an environment of the field device, or a vibration variable of a vibration of the field device. With regard to the vibration variable, the field device can be designed in such a way that the environmental sensor element 250 has a position sensor, for example a gyro sensor, for determining the vibration variable.

[0048] Furthermore, all field devices 101-105 each have a field device electronic unit 260 which is at least configured to receive the primary process variable F, p, T, R, D from a superordinate process control unit 300 and/or send it to the process control unit 300. In addition, the field device electronic unit 260 is also configured to send the secondary environmental variable 201-205 to a superordinate database and analysis platform 400, for example a cloud-computing-based platform. Especially, the field device electronic unit 260 may be configured such that the secondary environmental variable 201-205 is sent wirelessly to the superordinate database and analysis platform 400. For example, the secondary environmental variables can be transmitted by means of Bluetooth (Low Energy), 6LoWPAN, WirelessHART, 6TiSCH, ISA 100.11a, Zigbee (IP), WIA PA or WIA FA, WLAN or corresponding technologies or corresponding protocols.

[0049] In order to keep data throughput as low as possible, the field device electronic unit 260 may furthermore be configured to transmit the secondary environmental variable 201-205 at different transmission frequencies.

[0050] In order to determine a spatial or geographic position of the field device 101-105 within the automation system 500, it can also be provided that at least parts of the field devices have a GPS sensor element 270.

[0051] FIG. 2 shows a schematic representation of an automation technology system comprising an automation system 500 with five field devices 101-105 arranged spatially differently from one another and a database and analysis platform 400, which is arranged outside the automation system 500 in the example shown. This means that at least parts of the resources of the database and analysis platform 400 are located outside the system 500. Of course, it is also conceivable for the database and analysis platform 400 to be arranged exclusively inside the automation system 500. This means that all the resources of the database and analysis platform 400 are located inside the system 500. The database and analysis platform 400 can be designed in such a way that only a defined user group can or may access it. The defined user group usually comprises users that are to be assigned to the system operator, for example they may be the maintenance personnel of the system operator. As an alternative or in addition thereto, the defined user group may comprise users that cannot be assigned directly to the system operator, for example service technicians of the field device manufacturer.

[0052] The field devices 101-105 arranged in a spatially or geographically distributed fashion in the automation system 500 are designed in accordance with the above-described embodiments and transmit the primary process variable F, p, T, R, D to a superordinate process control unit 300 and/or receive the primary process variable F, p, T, R, D therefrom in order to thus control a process running in the system 500. In FIG. 2, the transmission of the primary process variables F, p, T, R and D is exemplarily indicated by dash-dot arrows.

[0053] The database and analysis platform 400, which is, for example, a cloud-computing-based platform, is in data communication with the field devices 101-105 in order to thus be able to transmit the secondary environmental variable 201-205. In FIG. 2, the transmission of the secondary environmental variable 201-205 is exemplarily indicated by dashed arrows. For example, the secondary environmental variable 201-205 of the individual field devices 101-105 may be transmitted by one of the previously listed technologies or protocols for wireless data transmission.

[0054] The secondary environmental variables 201-205 acquired and transmitted by the field devices 101-105 are used by the database and analysis platform 400 to monitor the automation system 500. For this purpose, the database and analysis platform 400 compares the secondary environmental variables 201-205 with comparative environmental variables 211-215 in order to be able to detect an unusual state 600 in the system 500.

[0055] The comparative environmental variables 211-215 represent the environmental variable of the respective field device 101-105 in a usual state and preferably relate to at least one field device of the automation system or a partial area of the automation system or also to an entire automation system. The comparative environmental variables 211-215 are supplied to the database and analysis platform 400, especially, before the actual monitoring. In FIG. 2, this is indicated by solid arrows. For example, at least for parts of the field devices 101-106, the database and analysis platform 400 may be provided with a field-device-specific comparative value 221-225, which for the corresponding field device 101-105 specifically maps the secondary environmental variable 201-205 at standard conditions that represent a usual state of the field devices 101-105. Especially, the field-device-specific comparative calibration and start-up variables relating to the respective field device 101-105 come into question as field-device-specific comparative variable. They can, for example, be acquired by the respective field device 101-105 when the automation system 500 is started up and/or when the corresponding field device 101-105 is calibrated, it being assumed that the conditions during the calibration and start-up of the automation system 500 represent a usual state.

[0056] Based on the comparative environmental variables 211-215 supplied to the database and analysis platform 400, said platform analyzes the secondary environmental variables 201-205 received from the field devices 101-105 for an unusual state, wherein provision may be made for the acquired environmental variables 201-205 to be transmitted with an information density and, only in the event that the unusual state 600 is detected, for the information density with which the environmental variables 201-205 were transmitted to date to be increased. This can be done, for example, in such a way that, as long as no unusual state has been detected, environmental variables 201-205 are transmitted to the database and analysis platform not by all field devices 101-105 but only by parts thereof, and in the event that an unusual state 600 is detected, the secondary environmental variables are transmitted by further field devices. For example, in addition to a gas composition variable acquired by a field device as a secondary environmental variable, image information of a further field device, which is preferably located in spatial proximity to the field device, can also be transmitted as a secondary environmental variable. As an alternative or in addition thereto, the information density can also be increased in such a way that the transmission frequency with which the secondary environmental variables 201-205 are transmitted is increased. For example, as long as no unusual state has been detected, the secondary environmental variable 201-205 may be transmitted every minute, and in the event that an unusual state was detected, may be transmitted every second. Increasing or enhancing the information density can serve to verify the unusual state detected.

[0057] The database and analysis platform 400 may also be configured to geographically and spatially isolate more specifically the position of a location 700 where the unusual state 600 occurs, after an unusual state 600 was detected. This can be achieved, for example, by assigning a TAG number or measuring point identification number 231-235 to the field devices 101-105 of the automation system and providing said number to the database and analysis platform 400. Today, such a TAG number or measuring point identification number 231-235 is common in automation systems 500 and uniquely identifies each field device 101-105 within the automation system 500 by a multiplicity of information, especially, also the information of an installation location, for example in accordance with DIN EN 61346. By means of such TAG numbers 231-235, the operators of automation systems 500 can, for example, fulfill their legal verification requirements. By providing the database and analysis platform 400 with an assignment to the respective field device 101-105 with respect to the respective TAG number 231-235, the position of the location 700 where the unusual state 600 occurs can be spatially or geographically isolated more specifically in the automation system 500. In FIG. 2, this is exemplarily indicated by a rectangle with a dashed line, which is intended to indicate the location where the unusual state occurs. In addition, the database and analysis platform 400 can also increase the information density on the basis of the TAG number 231-235 by determining by means of the TAG number 231-235 further field devices 101-105 which are located at a spatial distance from the field device 101-105 on which the unusual state was detected and whose acquired secondary environmental variables 201-205 are transmitted. Thus, in order to illustrate this using the example shown in FIG. 2, in the event that an unusual state 600 is detected on the basis of the secondary environmental variable 203 acquired by the field device 103, the database and analysis platform 400 can cause the environmental variables 201 and 202 acquired by the field devices 101 and 102 to be transmitted as well.

[0058] As an alternative or in addition thereto, the database and analysis platform 400 can be designed such that the unusual state 600 is evaluated with regard to its extent. For example, in the event that the unusual state 600 is detected, the database and analysis platform 400 may assign a priority to the unusual state 600. In this case, the priority can be identified in a wide variety of ways by the database and analysis platform 400. For example, the unusual states 600 can be identified to a user of the database and analysis platform 400 by means of a color marking that reflects the evaluated priority.

[0059] The database and analysis platform 400 may alternatively or additionally also be designed as a self-learning database and analysis platform, i.e., the platform is designed such that it learns independently. For example, the platform may have optimization methods that allow an unusual state 600 to be detected with a higher probability. This can take place in such a way that, in the event of a currently detected unusual state 600, the platform 400 learns, for example, by verifying or falsifying by means of a user input whether the currently detected unusual state 600 will also be detected again as an unusual state 600 in the future.

[0060] FIG. 3 shows exemplarily five signal profiles of the secondary environmental variable 201-205, each of which was acquired by a field device 101-105 of the automation system 500 shown in FIG. 2. The environmental variables 201-205 acquired by the field devices 101-105 were transmitted to the database and analysis platform 400 for monitoring the system, which database and analysis platform, upon comparing the secondary environmental variables 201-205 with comparative environmental variables 211-215, detected an unusual state 600 on the basis of the acquired environmental variables 201, 202 and 203.

LIST OF REFERENCE SYMBOLS

[0061] 101-105 Automation technology field devices [0062] 201-205 Secondary environmental variables [0063] 211-215 Comparative environmental variables [0064] 221-225 Field-device-specific comparative variable [0065] 231-235 TAG number or measuring point identification number [0066] 240 Sensor element or control element [0067] 250 Environmental sensor element [0068] 260 Field-device electronic unit [0069] 270 GPS sensor element [0070] 300 Superordinate process control unit [0071] 400 Database and analysis platform [0072] 500 Automation system [0073] 600 Unusual state [0074] 700 Location where the unusual state occurs [0075] F, p, T, R, D Primary process variable